Operator’s Manual€¦ · Fifth Edition • Third Printing Operator's Manual Part No. 133546...

Operator’s Manual

Original InstructionsFifth EditionThird PrintingPart No. 133546

withMaintenanceInformation

Z-30 20N RJZ-30 20N

Operator's Manual Fifth Edition • Third Printing

Z-30/20N • Z-30/20N RJ Part No. 133546

Copyright © 1995 by Genie Industries

First Edition: Fourth Printing, August 1996

Second Edition: Fourth Printing, July 2000

Third Edition: Third Printing, November 2009

Fourth Edition: Second Printing, November 2009

Fifth Edition: Third Printing, April 2012

"Genie" and "Z" are registered trademarks ofGenie Industries in the USA and many othercountries.

These machines comply withANSI A92.5CSA B354.4

Complies with EC Directive 2006/42/EC See EC Declaration of Conformity

Printed on recycled paper

Printed in U.S.A.

ImportantRead, understand and obey these safety rules andoperating instructions before operating this machine.Only trained and authorized personnel shall bepermitted to operate this machine. This manual shouldbe considered a permanent part of your machine andshould remain with the machine at all times. If youhave any questions, call Genie Industries.

Contents

PageSafety Rules .............................................................. 1Controls ..................................................................... 8Legend ..................................................................... 10Pre-operation Inspection........................................... 11Maintenance ............................................................. 13Function Tests .......................................................... 15Workplace Inspection ............................................... 20Operating Instructions .............................................. 21Decals ...................................................................... 26Transport and Lifting Instructions .............................. 30Specifications ........................................................... 33

Contact us:Internet: http://www.genielift.come-mail: [email protected]

Operator's ManualFifth Edition • Third Printing

Part No. 133546 Z-30/20N • Z-30/20N RJ 1

Safety Rules

Danger

Failure to obey the instructions andsafety rules in this manual will resultin death or serious injury.

Do Not Operate Unless:You learn and practice the principles of safemachine operation contained in this operator'smanual.

1 Avoid hazardous situations.

Know and understand the safety rulesbefore going on to the next section.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

You read, understand and obey themanufacturer's instructions and safety rules—safety and operator's manuals and machinedecals.

You read, understand and obey employer'ssafety rules and worksite regulations.

You read, understand and obey all applicablegovernmental regulations.

You are properly trained to safely operate themachine.


2 Z-30/20N • Z-30/20N RJ Part No. 133546

SAFETY RULES

Electrocution HazardsThis machine is not electrically insulated and willnot provide protection from contact with orproximity to electrical current.

Maintain safe distances from electrical power linesand apparatus in accordance with applicablegovernmental regulations and the following chart.

Voltage Minimum SafePhase to Phase Approach Distance

Feet Meters

0 to 300V Avoid Contact

300V to 50KV 10 3.05

50KV to 200KV 15 4.60

200KV to 350KV 20 6.10

350KV to 500KV 25 7.62

500KV to 750KV 35 10.67

750KV to 1000KV 45 13.72

Allow for platform movement, electrical line swayor sag, and beware of strong or gusty winds.

Keep away from the machine if it contactsenergized power lines. Personnel on the ground orin the platform must not touch or operate themachine until energized power lines are shut off.

Do not operate the machine during lightning orstorms.

Do not use the machine as a ground for welding.

Tip-over HazardsOccupants, equipment and materials shall notexceed the maximum platform capacity.

Maximum platform capacity 500 lbs 227 kg

Maximum platform capacity

Machine equipped withAircraft Protection Package 440 lbs 200 kg

Maximum occupants 2

The weight of options and accessories, such aspipe cradles, panel cradles and welders, willreduce the rated platform capacity and must befactored into the total platform load. See the decalson the options.

Do not raise or extend the boom unless themachine is on a firm, level surface.

Do not depend on the tilt alarm as a level indicator.The tilt alarm sounds in the platform only when themachine is on a severe slope.


Part No. 133546 Z-30/20N • Z-30/20N RJ 3

If the tilt alarm sounds while the boom is lowered:Do not extend, rotate or raise the boom abovehorizontal. Move the machine to a firm, levelsurface before raising the platform.

If the tilt alarm sounds when the platform is raised:Use extreme caution. Identify the condition of theboom on the slope as shown below. Follow thesteps to lower the boom before moving to a firm,level surface. Do not rotate the boom whilelowering.

If the tilt alarm sounds with theplatform uphill:

1 Lower the primary boom.

2 Lower the secondary boom.

3 Retract the primary boom.

If the tilt alarm sounds with theplatform downhill:

1 Retract the primaryboom.

2 Lower the secondaryboom.

3 Lower the primaryboom.

Do not alter or disable the limit switches.

Do not drive over 0.7 mph / 1 km/h with the primaryboom raised or extended or the secondary boomraised.

Do not use the platform controls to free a platformthat is caught, snagged or otherwise preventedfrom normal motion by an adjacent structure. Allpersonnel must be removed from the platformbefore attempting to free the platform using theground controls.

Do not raise the boom when wind speeds mayexceed 28 mph / 12.5 m/s. If wind speeds exceed28 mph / 12.5 m/s when the boom is raised, lowerthe boom and do not continue to operate themachine.

3

3

Do not operate the machine in strong or gustywinds. Do not increase the surface area of theplatform or the load. Increasing the area exposedto the wind will decrease machine stability.

Use extreme care and slow speeds while drivingthe machine in the stowed position across uneventerrain, debris, unstable or slippery surfaces andnear holes and drop-offs.

Do not drive the machine on or near uneventerrain, unstable surfaces or other hazardousconditions with the boom raised or extended.

Do not drive the machine on a slope that exceedsthe maximum uphill, downhill or side slope rating ofthe machine. Slope rating applies to machines inthe stowed position.

Maximum slope rating, stowed position

Counterweight uphill 35% 19°

Counterweight downhill 20% 11°

Side slope 25% 14°

Note: Slope rating is subject to ground conditionsand adequate traction.

Do not push off or pull toward any object outsideof the platform.

Maximum allowableside force - ANSI &CSA150 lbs / 667 N

Maximum allowablemanual force - CE90 lbs / 400 N

SAFETY RULES


4 Z-30/20N • Z-30/20N RJ Part No. 133546

SAFETY RULES

Do not use the machine as a crane.

Do not push the machine or other objects with theboom.

Do not contact adjacent structures with the boom.

Do not tie the boom or platform to adjacentstructures.

Do not place loads outside the platform perimeter.

Fall HazardsOccupants must wear asafety belt or harness andcomply with applicablegovernmental regulations.Attach lanyard to the anchorprovided in the platform.

Do not sit, stand or climb on the platform guardrails. Maintain a firm footing on the platform floor atall times.

Do not climb down from the platform when raised.

Keep the platform floor clear of debris.

Lower the platform entry mid-rail or close the entrygate before operating.

Do not alter or disable machine components that inany way affect safety and stability.

Do not replace items critical to machine stabilitywith items of different weight or specification.

Do not modify or alter an aerial work platformwithout prior written permission from themanufacturer. Mounting attachments for holdingtools or other materials onto the platform, toeboardsor guard rail system can increase the weight in theplatform and the surface area of the platform or theload.

Do not place or attach overhanging loads to anypart of this machine.

Do not place ladders or scaffolds in the platform oragainst any part of this machine.

Do not transport tools and materials unless they areevenly distributed and can be safely handled byperson(s) in the platform.

Do not use the machine on a moving or mobilesurface or vehicle.

Be sure all tires are in good condition and lug nutsare properly tightened.

Do not use batteries that weigh less than theoriginal equipment. Batteries are used ascounterweight and are critical to machine stability.Each battery must weigh a minimum of105 lbs / 47.6 kg. Each battery box includingbatteries must weigh a minimum of530 lbs / 240.4 kg.


Part No. 133546 Z-30/20N • Z-30/20N RJ 5

SAFETY RULES

Do not lower the boom unless the area below isclear of personnel and obstructions.

Limit travel speed according to the condition of theground surface, congestion, slope, location ofpersonnel, and any other factors which may causecollision.

Do not operate a boom in the path of any craneunless the controls of the crane have been lockedout and/or precautions have been taken to preventany potential collision.

No stunt driving or horseplay while operating amachine.

Collision HazardsBe aware of limited sightdistance and blind spotswhen driving or operating.

Be aware of boom position when rotating theturntable.

Check the work area for overhead obstructions orother possible hazards.

Be aware of crushing hazards when grasping theplatform guard rail.

Operators must comply with employer, job site andgovernmental rules regarding the use of personalprotective equipment.

Observe and use the color-coded direction arrowson the platform controls and drive chassis for driveand steer functions.


6 Z-30/20N • Z-30/20N RJ Part No. 133546

Decal LegendGenie product decals use symbols, color codingand signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

SAFETY RULES

Component Damage HazardDo not use the machine as a ground for welding.

Damaged Machine HazardsDo not use a damaged or malfunctioning machine.

Conduct a thorough pre-operation inspection of themachine and test all functions before each workshift. Immediately tag and remove from service adamaged or malfunctioning machine.

Be sure all maintenance has been performed asspecified in this manual and theGenie Z-30/20N Service Manual.

Be sure all decals are in place and legible.

Be sure the operator’s, safety and responsibilitiesmanuals are complete, legible and in the storagecontainer located on the platform.

Bodily Injury HazardDo not operate the machine with a hydraulic oil orair leak. An air leak or hydraulic leak can penetrateand/or burn skin.

Improper contact with components under anycover will cause serious injury. Only trainedmaintenance personnel should accesscompartments. Access by the operator is onlyadvised when performing a pre-operationinspection. All compartments must remain closedand secured during operation.


Part No. 133546 Z-30/20N • Z-30/20N RJ 7

SAFETY RULES

Battery Safety

Burn HazardsBatteries contain acid. Always wear protectiveclothing and eyewear when working with batteries.

Avoid spilling or contacting battery acid. Neutralizebattery acid spills with baking soda and water.

The battery pack must remain in an uprightposition.

Do not expose the batteries or the charger to wateror rain.

Explosion HazardsKeep sparks, flamesand lighted tobaccoaway from batteries.Batteries emit anexplosive gas.

The battery pack covermust remain off duringthe entire chargingcycle.

Do not contact the battery terminals or the cableclamps with tools that may cause sparks.

Component Damage HazardsDo not use any battery charger greater than 48V tocharge the batteries.

Both battery packs must be charged together.

Disconnect the battery pack plug before removingthe battery pack.

Electrocution HazardsConnect the battery charger toa grounded, AC 3-wireelectrical outlet only.

Inspect daily for damaged cord,cables and wires. Replacedamaged items beforeoperating.

Avoid electrical shock from contact with batteryterminals. Remove all rings, watches and otherjewelry.

Tip-over HazardDo not use batteries that weigh less than theoriginal equipment. Batteries are used ascounterweight and are critical to machine stability.Each battery must weigh a minimum of105 lbs / 47.6 kg. Each battery box includingbatteries must weigh a minimum of530 lbs / 240.4 kg.

Lifting HazardUse a forklift to remove or install the battery packs.


8 Z-30/20N • Z-30/20N RJ Part No. 133546

Controls

Platform Control Panel

1 Drive enable switch

2 Drive enable indicator light

3 Auxiliary power switch

4 Platform level switch

5 Horn button

6 Primary boom extend/retract switch

7 Red Emergency Stop button

8 Jib boom rotate switch (option)

9 Battery charge indicator and/or low voltageinterrupt (option)

10 Machine not level indicator light (if equipped)

11 Proportional control handle for drive functionand thumb rocker for steer function

12 Platform overload indicator light (if equipped)

13 Function Override - Aircraft Protection Package(if equipped)

14 Boom function speed controller

15 Jib boom up/down switch

16 Secondary boom up/down switch

17 Primary boom up/down switch

18 Turntable rotate switch

19 Platform rotate switch

20 Not used

To drive, hold drive enableswitch up or down andslowly move drive controlhandle. Machine may drivein opposite direction thatthe drive and steer controlsare moved.

Use color-coded directionarrows on this panel anddrive chassis to identify thedirection machine will travel.

Light on indicates that boomhas moved past a non-steertire and drive function isturned off.

DRIVEENABLEOPERATION

STOP

F

E

12

CREEP

19 18 17 16 13 15 14 20 20

20

20

20

12

11

10987654

3

2

1


Part No. 133546 Z-30/20N • Z-30/20N RJ 9

CONTROLS

Ground Control Panel

1 Secondary boom up/down switch

2 Turntable rotate switch

3 Platform rotate switch

4 Platform level switch

5 Primary boom extend/retract switch

6 Auxiliary power switch

7 Key switch for platform/off/ground selection

8 Hour meter

9 Red Emergency Stop button

10 10A breaker for electrical circuits

11 Platform overload indicator light (if equipped)

12 Jib boom rotate switch (option)

13 Jib boom up/down switch

14 Primary boom up/down switch

15 Function enable switch


10 Z-30/20N • Z-30/20N RJ Part No. 133546

Legend

1 Non-steer tire

2 Battery box

3 Steer tire

4 Power to charger (between steer tires)

5 Ground controls

6 Secondary boom

7 Primary boom

8 Jib boom

9 Platform controls

10 Platform

11 Lanyard anchorage point

12 Sliding mid-rail

13 Manual storage container

14 Foot switch


Part No. 133546 Z-30/20N • Z-30/20N RJ 11

Pre-operation Inspection



2 Always perform a pre-operationinspection.

Know and understand the pre-operationinspection before going on to the nextsection.




FundamentalsIt is the responsibility of the operator to perform apre-operation inspection and routine maintenance.

The pre-operation inspection is a visual inspectionperformed by the operator prior to each work shift.The inspection is designed to discover if anythingis apparently wrong with a machine before theoperator performs the function tests.

The pre-operation inspection also serves todetermine if routine maintenance procedures arerequired. Only routine maintenance items specifiedin this manual may be performed by the operator.

Refer to the list on the next page and check eachof the items.

If damage or any unauthorized variation fromfactory delivered condition is discovered, themachine must be tagged and removed fromservice.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications. After repairs arecompleted, the operator must perform apre-operation inspection again before going on tothe function tests.

Scheduled maintenance inspections shall beperformed by qualified service technicians,according to the manufacturer's specifications andthe requirements listed in the responsibilitiesmanual.


12 Z-30/20N • Z-30/20N RJ Part No. 133546

Pre-operation Inspection

R Be sure that the operator's, safety andresponsibilities manuals are complete, legibleand in the storage container located on theplatform.

R Be sure that all decals are legible and in place.See Decals section.

R Check for hydraulic oil leaks and proper oillevel. Add oil if needed. See Maintenancesection.

R Check for battery fluid leaks and proper fluidlevel. Add distilled water if needed. SeeMaintenance section.

Check the following components or areas fordamage, improperly installed or missing parts andunauthorized modifications:

R Electrical components, wiring and electricalcables

R Hydraulic power unit, reservoir, hoses,fittings, cylinders and manifolds

R Drive and turntable motors and drive hubs

R Boom wear pads

R Tires and wheels

R Limit switches

R Nuts, bolts and other fasteners

R Platform entry mid-rail/gate

R Beacon and alarms (if equipped)

PRE-OPERATION INSPECTION

Check entire machine for:

R Cracks in welds or structural components

R Dents or damage to machine

R Be sure that all structural and other criticalcomponents are present and all associatedfasteners and pins are in place and properlytightened.

R Be sure that both battery packs are in place,latched and properly connected.

R After you complete your inspection, be sure thatall compartment covers are in place andlatched.


Part No. 133546 Z-30/20N • Z-30/20N RJ 13

Maintenance

Observe and Obey:Only routine maintenance items specified in thismanual shall be performed by the operator.

Scheduled maintenance inspections shall becompleted by qualified service technicians,according to the manufacturer's specificationsand the requirements specified in theresponsibilities manual.

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will berequired to perform this procedure.

Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes in oillevel that might indicate the presence of hydraulicsystem problems.

1 Be sure that the boom is in the stowed position.

2 Check the hydraulic oil level.

Result: The hydraulic oil level should be,between the FULL and ADD marks on thehydraulic reservoir.

3 Add hydraulic oil if necessary.

Hydraulic oil specifications

Hydraulic oil type Chevron Rando HDPremium MV equivalent


14 Z-30/20N • Z-30/20N RJ Part No. 133546

Check the Batteries

Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

Perform this test after fullycharging the batteries.

1 Put on protective clothing and eyewear.

2 Be sure that the battery cable connections aretight and free of corrosion.

Standard Batteries

3 Remove the battery vent caps.

4 Check the battery acid level. If needed,replenish with distilled water to the bottom ofthe battery fill tube. Do not overfill.

5 Install the vent caps.

MAINTENANCE

Scheduled MaintenanceMaintenance performed quarterly, annually andevery two years must be completed by a persontrained and qualified to perform maintenance onthis machine according to the procedures found inthe service manual for this machine.

Machines that have been out of service for morethan three months must receive the quarterlyinspection before they are put back into service.


Part No. 133546 Z-30/20N • Z-30/20N RJ 15

Function Tests




3 Always perform function tests prior touse.

Know and understand the function testsbefore going on to the next section.



1 Select a test area that is firm, level and free ofobstruction.

At the Ground Controls2 Turn the key switch to ground control.

3 Pull out the red Emergency Stop button tothe on position.

Result: The beacon (if equipped) should flash.

Test Emergency Stop

4 Push in the red Emergency Stop button to theoff position.

Result: All ground and platform control functionsshould not operate.


FundamentalsThe function tests are designed to discover anymalfunctions before the machine is put intoservice. The operator must follow the step-by-stepinstructions to test all machine functions.

A malfunctioning machine must never be used. Ifmalfunctions are discovered, the machine must betagged and removed from service. Repairs to themachine may only be made by a qualified servicetechnician, according to the manufacturer’sspecifications.

After repairs are completed, the operator mustperform a pre-operation inspection and functiontests again before putting the machine into service.


16 Z-30/20N • Z-30/20N RJ Part No. 133546

FUNCTION TESTS

Test Auxiliary Controls

11 Turn the key switch to ground control.

12 Simultaneously hold theauxiliary power switch on andactivate each boom functiontoggle switch.

Note: To conserve battery power, test eachfunction through a partial cycle.

Result: All boom functions should operate.

13 Turn the key switch to platform control.

At the Platform ControlsTest Emergency Stop

14 Push in the platform red Emergency Stopbutton to the off position.

Result: All platform control functions should notoperate.

Test the Horn

15 Pull out the red Emergency Stop button to theon position.

16 Push the horn button.

Result: The horn should sound.

Test the Foot Switch

17 Do not press down the foot switch. Activateeach machine function.

Result: The machine functions should notoperate.

Test the Boom Functions

6 Do not hold the function enableswitch to either side. Attemptto activate each boom andplatform function toggle switch.

Result: All boom and platform functions shouldnot operate.

7 Hold the function enable switch to either sideand activate each boom and platform functiontoggle switch.

Result: All boom and platform functions shouldoperate through a full cycle. The descent alarm(if equipped) should sound while the boom islowering.

Test the Tilt Sensor

8 Pull out the platform red Emergency Stopbutton to the on position. Turn the key switch toplatform control.

9 Open the ground control side turntable coverand locate the tilt sensor next to the functionmanifold.

10 Press down one side of the tiltsensor.

Result: The alarm, located in theplatform, should sound.


Part No. 133546 Z-30/20N • Z-30/20N RJ 17

FUNCTION TESTS

Test Machine Functions

18 Press down the foot switch.

19 Activate each machine function toggle switch.

Result: All boom/platform functions shouldoperate through a full cycle.

Note: Control the speed of boom functions byadjusting the boom function speed controller. Driveand steer functions are not affected by the boomfunction speed controller.

Test the Steering


21 Depress the thumb rocker switch on top of thedrive control handle in the direction identified bythe blue triangle on the control panel.

Result: The steer wheels should turn in thedirection that the blue triangles point on thedrive chassis.

22 Depress the thumb rocker switch in thedirection identified by the yellow triangle on thecontrol panel.

Result: The steer wheels should turn in thedirection that the yellow triangles point on thedrive chassis.

Test Drive and Braking


24 Slowly move the drive control handle in thedirection indicated by the blue arrow on thecontrol panel until the machine begins to move,then return the handle to the center position.

Result: The travel alarm should sound. Themachine should move in the direction that theblue arrow points on the drive chassis, thencome to an abrupt stop.

25 Slowly move the drive control handle in thedirection indicated by the yellow arrow on thecontrol panel until the machine begins to move,then return the handle to the center position.

Result: The travel alarm should sound. Themachine should move in the direction that theyellow arrow points on the drive chassis, thencome to an abrupt stop.

Note: The brakes must be able to hold the machineon any slope it is able to climb.


18 Z-30/20N • Z-30/20N RJ Part No. 133546

Test Limited Drive Speed


27 Raise the primary boom 1 foot / 30 cm.

28 Slowly move the drive control handle to the fulldrive position.

Result: The maximum achievable drive speedwith the primary boom raised should notexceed 1 foot / 30 cm per second.

29 Lower the boom to the stowed position.

30 Raise the secondary boom 1 foot / 30 cm.


Result: The maximum achievable drive speedwith the secondary boom raised should notexceed 1 foot / 30 cm per second.


33 Extend the primary boom 1 foot / 30 cm.


Result: The maximum achievable drive speedwith the primary boom extended should notexceed 1 foot / 30 cm per second.

If the drive speed with the primary boom raised orextended or the secondary boom raised exceeds1 foot / 30 cm per second, immediately tag andremove the machine from service.

Test the Drive Enable System

35 Press down the foot switch and retract theprimary boom to the stowed position.

36 Rotate the turntable until the boom moves pastone of the non-steer wheels.

Result: The drive enableindicator light should comeon and remain on whilethe boom is anywhere inthe range shown.

37 Move the drive control handle off center.

Result: The drive function should not operate.

38 Hold the drive enable toggle switch up or downand slowly move the drive control handle offcenter.

Result: The drive function should operate.

Note: When the drive enable system is in use, themachine may drive in the opposite direction thatthe drive and steer control handle is moved.

Use the color-codeddirection arrows on theplatform controls and thedrive chassis to identify thedirection of travel.

FUNCTION TESTS

Blue

Yellow


Part No. 133546 Z-30/20N • Z-30/20N RJ 19

Test Auxiliary Controls


40 Simultaneously hold the auxiliary power switchon and activate each function control handle ortoggle switch.

Note: To conserve battery power, test eachfunction through a partial cycle.

Result: All boom, steer and drive functionsshould operate.

Test the Lift/Drive Select Function(if equipped)


42 Move the drive control handle off center andactivate a boom function toggle switch.

Result: No boom functions should operate. Themachine will move in the direction indicated onthe control panel.

FUNCTION TESTS


20 Z-30/20N • Z-30/20N RJ Part No. 133546

Workplace Inspection

Workplace InspectionBe aware of and avoid the following hazardoussituations:

· drop-offs or holes

· bumps, floor obstructions or debris

· sloped surfaces

· unstable or slippery surfaces

· overhead obstructions and high voltageconductors

· hazardous locations

· inadequate surface support to withstand all loadforces imposed by the machine

· wind and weather conditions

· the presence of unauthorized personnel

· other possible unsafe conditions






Know and understand the workplaceinspection before going on to the nextsection.


FundamentalsThe workplace inspection helps the operatordetermine if the workplace is suitable for safemachine operation. It should be performed by theoperator prior to moving the machine to theworkplace.

It is the operator's responsibility to read andremember the workplace hazards, then watch forand avoid them while moving, setting up andoperating the machine.


Part No. 133546 Z-30/20N • Z-30/20N RJ 21

Operating Instructions







FundamentalsThe Operating Instructions section providesinstructions for each aspect of machine operation.It is the operator's responsibility to follow all thesafety rules and instructions in the operator's,safety and responsibilities manuals.

Using the machine for anything other than liftingpersonnel, along with their tools and materials, toan aerial worksite is unsafe and dangerous.

Only trained and authorized personnel should bepermitted to operate a machine. If more than oneoperator is expected to use a machine at differenttimes in the same work shift, they must all bequalified operators and are all expected to follow allsafety rules and instructions in the operator's,safety and responsibilities manuals. That meansevery new operator should perform a pre-operationinspection, function tests, and a work placeinspection before using the machine.


22 Z-30/20N • Z-30/20N RJ Part No. 133546

OPERATING INSTRUCTIONS

Emergency StopPush in the red Emergency Stop button to the offposition at the ground or platform controls to stopall machine functions.

Repair any function that operates when the redEmergency Stop button is pushed in.

Selecting and operating the ground controls willoverride the platform red Emergency Stop button.

Auxiliary ControlsUse auxiliary power if the primary power sourcefails.

1 Be sure both battery packs are connectedbefore operating the machine.

2 Turn the key switch to ground or platformcontrol.

3 Pull out the red Emergency Stop button to theon position.

4 Press down the foot switch when operating theauxiliary controls from the platform.

5 Simultaneously hold theauxiliary power switch on andactivate the desired function.

The boom, steer and drive functions will operatewith auxiliary power.

Operation from Ground1 Be sure both battery packs are connected

before operating the machine.

2 Turn the key switch to ground control.


To Position Platform

1 Hold the function enable switch toeither side.

2 Move the appropriate toggle switch according tomarkings on the control panel.

Drive and steer functions are not available from theground controls.

Operation from Platform1 Be sure that both battery packs are connected

before operating the machine.

2 Turn the key switch to platform control.

3 Pull out both ground and platform redEmergency Stop buttons to the on position.

To Position Platform

1 Set the boom function speed controller to thedesired speed.

Note: Drive and steer functions are not affected bythe boom function speed controller.


3 Move the appropriate toggle switch according tothe markings on the control panel.

To Steer


2 Turn the steer wheels with the thumb rockerswitch located on top of the drive controlhandle.

Use the color-coded direction triangles on theplatform controls and the drive chassis to identifythe direction the wheels will turn.


Part No. 133546 Z-30/20N • Z-30/20N RJ 23

To Drive


2 Increase speed: Slowly move the drive controlhandle off center.

Decrease speed: Slowly move the drive controlhandle toward center.

Stop: Return the drive control handle to center orrelease the foot switch.

Use the color-coded direction arrows on the platformcontrols and the drive chassis to identify thedirection the machine will travel.

Machine travel speed is restricted when the boomsare raised or extended.

Battery condition will affect machine performance.

Driving on a slope

Determine the uphill, downhill and side slope ratingsfor the machine and determine the slope grade.

Maximum slope rating, counterweightuphill (gradeability): 35% (19°)

Maximum slope rating, counterweightdownhill: 20% (11°)

Maximum side slope rating: 25% (14°)

Note: Slope rating is subject to groundconditions and adequate traction. The termgradeability applies to the counterweight uphillconfiguration only.

Be sure the boom is below horizontal and theplatform is between the non-steer wheels.

To determine the slope grade:

Measure the slope with a digital inclinometer ORuse the following procedure.

You will need:

carpenter’s level

straight piece of wood, at least 3 feet / 1 m long

tape measure

Lay the piece of wood on the slope.

At the downhill end, lay the level on the top edge ofthe piece of wood and lift the end until the piece ofwood is level.

While holding the piece of wood level, measure thedistance from the bottom of the piece of wood tothe ground.

Divide the tape measure distance (rise) by thelength of the piece of wood (run) and multiply by100.

Example:

Piece of wood = 144 inches (3.6 m)

Run = 144 inches (3.6 m)

Rise = 12 inches (0.3 m)

12 in y 144 in = 0.083 x 100 = 8.3% grade

0.3 m y 3.6 m = 0.083 x 100 = 8.3% grade

If the slope exceeds the maximum uphill, downhillor side slope rating, then the machine must bewinched or transported up or down the slope. SeeTransport and Lifting section.



24 Z-30/20N • Z-30/20N RJ Part No. 133546

Drive Enable

Light on indicates that the boom hasmoved past either non-steer wheeland the drive function has beeninterrupted.

To drive, hold the drive enable switch up or downand slowly move the drive control handle off center.

Be aware that the machine may move in theopposite direction that the drive and steer controlsare moved.

Always use the color-coded direction arrows on theplatform controls and the drive chassis to identifythe direction the machine will travel.

Low Voltage Interrupt(if equipped)Machines equipped with Low Voltage Interrupt willlose primary and secondary boom up functionsfrom the platform when batteries are low.

Machine Not Level IndicatorLight (if equipped)

Light on indicates the machine is notlevel. The tilt alarm will be soundingwhen this light is on. Move themachine to a firm level surface.


Platform Overload IndicatorLight (if equipped)

Light flashing indicates theplatform is overloaded and nofunctions will operate.

Remove weight from the platformuntil the light goes off.

Fall ProtectionPersonal fall protection equipment (PFPE) isrequired when operating this machine.

All PFPE must comply with applicablegovernmental regulations, and must be inspectedand used in accordance with the PFPEmanufacturer’s instructions.

After Each Use1 Select a safe parking location—firm level

surface, clear of obstruction and traffic.


3 Rotate the turntable so that the boom isbetween the non-steer wheels.

4 Turn the key switch to the off position andremove the key to secure from unauthorizeduse.

5 Chock the wheels.

6 Charge the batteries.

Aircraft Protection Package(If equipped)If the platform bumpers come in contact withaircraft components, the machine will shut downand no functions will operate.

Move the function override toggle switch to eitherside to operate the machine.


Part No. 133546 Z-30/20N • Z-30/20N RJ 25


Battery and Charger Instructions

Observe and Obey:Do not use external charger or booster batteries.

Charge the batteries in a well-ventilated area.

Use proper AC input voltage for charging asindicated on the charger.

Use only Genie authorized batteries andcharger.

To Charge Battery1 Be sure the batteries are connected before

charging the batteries.

2 Open the battery compartment. Thecompartment should remain open for the entirecharging cycle.

Maintenance-free batteries

1 Connect the battery charger to a grounded ACcircuit.

2 The charger will indicate when the battery is fullycharged.

Standard Batteries

1 Remove the battery vent caps and check thebattery acid level. If necessary, add onlyenough distilled water to cover the plates. Donot overfill prior to the charge cycle.

2 Replace the battery vent caps.

3 Connect the battery charger to a grounded ACcircuit.

4 The charger will indicate when the battery is fullycharged.

5 Check the battery acid level when the chargingcycle is complete. Replenish with distilled waterto the bottom of the fill tube. Do not overfill.

Dry Battery Filling and ChargingInstructions1 Remove the battery vent caps and permanently

remove the plastic seal from the battery ventopenings.

2 Fill each cell with battery acid (electrolyte) untilthe level is sufficient to cover the plates.

Do not fill to maximum level until the battery chargecycle is complete. Overfilling can cause the batteryacid to overflow during charging. Neutralize batteryacid spills with baking soda and water.

3 Install the battery vent caps.

4 Charge the battery.

5 Check the battery acid level when the chargingcycle is complete. Replenish with distilled waterto the bottom of the fill tube. Do not overfill.


26 Z-30/20N • Z-30/20N RJ Part No. 133546

Decals

Part No. Decal Description Quantity

27564 Danger - Electrocution Hazard 2

28161 Warning - Crushing Hazard 3

28164 Notice - Hazardous Materials 1

28165 Notice - Foot Switch 1

28171 Label - No Smoking 1

28174 Label - Power to Platform, 230V 2

28175 Caution - Compartment Access 1

28176 Notice - Missing Manuals 1

28177 Warning - Platform Rotate 2

28181 Warning - No Step or Ride 1


28236 Warning - Failure To Read . . . 1

28372 Caution - Component Damage 2

31060 Danger - Tip-over Hazard, Interlock 4

31508 Notice - Power to Charger 1

31785 Notice - Battery Charger Instructions 2

31787 Danger - Tip-over, Batteries 2

31788 Danger - Battery/Charger Safety 2

32728 Label - Inverter Option Patch 1

35542 Notice - Lug Nuts 4

37052 Notice - Maximum Load, 500 lbs / 227 kg 1

37053 Arrow - Blue 1

37054 Arrow - Yellow 1

37055 Triangle - Blue 2

37056 Triangle - Yellow 2

40434 Label - Lanyard Anchorage 2


44248 Label - Maximum Capacity, 440 lbs(Aircraft Protection Package) 1

44980 Label - Power to Charger, EE 1

44981 Label - Air Line to Platform 2

44986 Notice - Max Side Force, 90 lbs / 400 N 1

46468 Label - Function Override(Aircraft Protection Package) 1

52947 Notice - Operating Instructions, Ground 1

52968 Cosmetic - Genie Boom 1

62928 Cosmetic - Genie Z-30/20N 1


65171 Label - Circuit Breaker & Status Light 1

72081 Platform Control Panel 1

72167 Cosmetic - Genie Z-30/20N RJ 1

72833 Label - Open 2

72867 Label - Work Lights Option Patch 1

72999 Label - Environ MV46 1

82161 Label - UCON Hydrolube, HP-5046 1

82366 Label - Chevron Rando 1

82592 Ground Control Panel 1

97890 Danger - General Safety 2

97893 Notice - Max Side Force, 150 lbs / 667 N 1

97894 Notice - Operating Instructions, Platform 1

114117 Notice - Battery Connection Diagram 2

114397 Danger - Tilt-Alarm 1

133286 Label - Power to Charger, Universal 1

139586 Label - Wheel Load 4

Inspection for Decals with WordsDetermine whether the decals on your machinehave words or symbols. Use the appropriateinspection to verify that all decals are legible and inplace.


Part No. 133546 Z-30/20N • Z-30/20N RJ 27

72081

97890

114397

97894

2823628176

2816544981

97893or 44986

28235or 28174

114117

114117

31785

3178531508

31787

31787

31788

31788

37053

3705452968

37056

3705528175

37055

37056

31060

44980or 133286

31060

2816452947

28171

SerialPlate

2818128161

82592

97890

139586

62929

35542

35542

28372

65171

31060

28177 40434

4498162929

7283335542

139586

139586

35542

2837228235or 28174

27564

28161

28161

31060

62928or 72167

28177

40434

27564

72833

7286732728

82366or 82161or 72999

37052or 44248

46468

DECALS

GroundControls

Side

Platform

Chassis

PowerUnitSide

Shading indicates decal is hiddenfrom view, i.e., under covers.


28 Z-30/20N • Z-30/20N RJ Part No. 133546

DECALS

Inspection for Decals withSymbolsDetermine whether the decals on your machinehave words or symbols. Use the appropriateinspection to verify that all decals are legible and inplace.


28171 Label - No Smoking 1



32728 Label - Inverter Option Patch 1

37053 Arrow - Blue 1

37054 Arrow - Yellow 1

37055 Triangle - Blue 2

37056 Triangle - Yellow 2

40434 Label - Lanyard Anchorage 2

44981 Label - Air Line to Platform 2

46468 Label - Function Override(Aircraft Protection Package) 1

52968 Cosmetic - Genie Boom 1



72081 Platform Control Panel 1

72167 Cosmetic - Genie Z-30/20N RJ 1

72867 Label - Work Light Option Patch 1

82472 Warning - Crushing Hazard 3


82481 Danger - Battery Safety 2

82487 Label - Operating Instructions 2

82544 Danger - Electrocution Hazard 2

82548 Warning - Platform Rotate 2

82592 Ground Control Panel 1

82601 Danger - Maximum Capacity, 227 kg 1

82602 Danger - Maximum Side Force, 667 N 1

82604 Danger - Maximum Manual Force, 400 N 1

82610 Label - Circuit Breaker & Status Light 1

82611 Label - Drive Enable Patch 1

82612 Label - Maximum Capacity, 200 kg(Aircraft Protection Package) 1

97815 Label - Lower Mid-rail 1

114343 Label - Emergency Lowering 1

133286 Label - Power to Charger 1

139586 Label - Wheel Load 4


Part No. 133546 Z-30/20N • Z-30/20N RJ 29

62929

82610

82544

82592

82481

82481

SerialPlate

82548

37053

37054

52968

37056

37055

37055

37056

82548

40434

40434

82544

82472

82472

44981

44981

133286

62928or 72167

62929139586

139586

139586

82602or 82604

8248797815

82487

46468

82611

2817428235 or

2817428235 or

82472

28171

114343

3272872867

Safety Tape

Safety Tape

72081

82601or 82612

GroundControls

Side

Platform

Chassis

PowerUnitSide

DECALS

Shading indicates decal is hiddenfrom view, i.e., under covers.


30 Z-30/20N • Z-30/20N RJ Part No. 133546

Free-wheel Configuration forWinching1 Chock the wheels to prevent the machine from

rolling.

2 Release the non-steer wheel brakesby turning over thedrive hubdisconnect caps.

3 Be sure the winch line is properly secured tothe drive chassis tie points and the path is clearof all obstructions.

After the machine is loaded:

1 Chock the wheels to prevent the machine fromrolling.

2 Apply the non-steer wheel brakes by turningover the drive hub disconnect caps.

Towing the Genie Z-30/20N is not recommended.If the machine must be towed, do not exceed2 mph / 3.2 km/h.

Observe and Obey:Common sense and planning must be appliedto control the movement of the machine whenlifting it with a crane or forklift.

The transport vehicle must be parked on a levelsurface.

The transport vehicle must be secured toprevent rolling while the machine is beingloaded.

Be sure the vehicle capacity, loading surfacesand chains or straps are sufficient to withstandthe machine weight. See the serial plate for themachine weight.

The machine must be on a level surface orsecured before releasing the brakes.

Do not drive the machine on a slope thatexceeds the slope or side slope rating. SeeDriving on a Slope in the Operating Instructionssection.

If the slope of the transport vehicle bed exceedsthe uphill or downhill maximum slope rating, themachine must be loaded and unloaded using awinch as described.

Transport and Lifting Instructions

DisengagePosition

EngagePosition


Part No. 133546 Z-30/20N • Z-30/20N RJ 31

Securing to Truck or Trailer forTransitAlways chock the machine wheels in preparationfor transport.

Turn the key switch to the off position and removethe key before transporting.

Inspect the entire machine for loose or unsecureditems.

Securing the Chassis

Use the tie points on the drive chassis foranchoring down to the transport surface.

Use chains or straps of ample load capacity.

Use a minimum of 4 chains.

Adjust the rigging to prevent damage to the chains.

Securing the Platform

Make sure the jib and platform are in the stowedposition.

Place a block under the edge of the platformbeneath the platform entry.

Secure the platform with a nylon strap placed overthe platform mount near the platform rotator (seebelow). Do not use excessive downward forcewhen securing the boom section.

TRANSPORT AND LIFTING INSTRUCTIONS


32 Z-30/20N • Z-30/20N RJ Part No. 133546

Observe and Obey:Only qualified riggers should rig and lift themachine.

Be sure the crane capacity, loading surfacesand straps or lines are sufficient to withstandthe machine weight. See the serial plate for themachine weight.

Lifting InstructionsFully lower and retract the boom. Fully lower thejib. Remove all loose items on the machine.

Determine the center of gravity of your machineusing the table and the picture on this page.

Attach the rigging only to the designated liftingpoints on the machine. There are four lifting pointson the chassis.

Adjust the rigging to prevent damage to themachine and to keep the machine level.

X Axis 31.19 in 79.2 cm

Y Axis 34.34 in 87.2 cm

TRANSPORT AND LIFTING INSTRUCTIONS


Part No. 133546 Z-30/20N • Z-30/20N RJ 33

Specifications

Z-30/20N without rotating jib

Height, working maximum 36 ft 11 m

Height, platform maximum 30 ft 9.1 m

Height, stowed maximum 6 ft 7 in 2 m

Horizontal reach maximum 21 ft 5 in 6.5 m

Width 3 ft 11 in 1.2 m

Length, stowed 16 ft 9 in 5.1 m

Maximum load capacity 500 lbs 227 kg

Maximum wind speed 28 mph 12.5 m/s

Wheelbase 5 ft 3 in 1.6 m

Turning radius (outside) 10 ft 7 in 3.2 m

Turning radius (inside) 5 ft 5 in 1.7 m

Turntable rotation 359°

Turntable tailswing 0°

Power source 8 Group 903, L-16,6V 390AH Batteries

Controls 24V DC proportional

Platform dimensions, 46 in x 30 in(length x width) 1.8 m x 76 cm

Platform leveling self-leveling

Platform rotation 180°

AC outlet in platform standard

Hydraulic pressure, maximum 2800 psi(boom functions) 193 bar

System voltage 48V

Tire size (solid rubber) 22 x 7 x 173/4 in56 x 18 x 45 cm

Vibration value does not exceed 2.5 m/s2

Ground clearance 31/2 in 8.9 cm

Weight See Serial Plate(Machine weights vary with option configurations)

Drive speeds

Drive speed, stowed 3.0 mph 4.8 km/h40 ft/9 sec 12.2 m/9 sec

Drive speed, 0.7 mph 1.0 km/hbooms raised 40 ft/40 sec 12.2 m/40 secor extended




Side slope 25% 14°

Note: Slope rating is subject to ground conditions andadequate traction.

Airborne noise emissions

Sound pressure level at ground workstation < 70 dBA

Sound pressure level at platform workstation < 70 dBA

Floor Loading Information

Tire load, maximum 7350 lbs 3334 kg

Tire contact pressure (per tire) 103 psi 710 kPa7.24 kg/cm2

Occupied floor pressure 535 psf 25.62 kPa2612 kg/m2

Note: Floor loading information is approximate anddoes not incorporate different option configurations. Itshould be used only with adequate safety factors.

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice or obligation.


34 Z-30/20N • Z-30/20N RJ Part No. 133546

Z-30/20N with rotating jib

Height, working maximum 35 ft 2 in 10.7 m

Height, platform maximum 29 ft 2 in 8.8 m

Height, stowed maximum 6 ft 7 in 2 m

Horizontal reach maximum 21 ft 6.4 m

Width 3 ft 11 in 1.2 m

Length, stowed 17 ft 5 in 5.3 m

Maximum load capacity 500 lb 227 kg

Maximum wind speed 28 mph 12.5 m/s

Wheelbase 5 ft 3 in 1.6 m

Turning radius (outside) 9 ft 10 in 3.0 m

Turning radius (inside) 5 ft 5 in 1.7 m

Turntable rotation 359°

Turntable tailswing 0°

Power source 8 Group 903, L-16,6V 390AH Batteries

Controls 24V DC proportional

Platform dimensions, 46 in x 30 in(length x width) 1.8 m x 76 cm

Platform leveling self-leveling

Platform rotation 180°

Jib rotation 180°

AC outlet in platform standard

Hydraulic pressure, maximum 2800 psi(boom functions) 193 bar

System voltage 48V

Tire size (solid rubber) 22 x 7 x 173/4 in56 x 18 x 45 cm

Vibration value does not exceed 2.5 m/s2

Ground clearance 31/2 in 8.9 cm

Weight See Serial Plate(Machine weights vary with option configurations)

Drive speeds

Drive speed, stowed 3.0 mph 4.8 km/h40 ft/9 sec 12.2 m/9 sec

Drive speed, 0.7 mph 1.0 km/hbooms raised 40 ft/40 sec 12.2 m/40 secor extended




Side slope 25% 14°

Note: Slope rating is subject to ground conditions andadequate traction.

Airborne noise emissions

Sound pressure level at ground workstation < 70 dBA

Sound pressure level at platform workstation < 70 dBA

Floor Loading Information

Tire load, maximum 7500 lbs 3402 kg

Tire contact pressure (per tire) 103 psi 710 kPa7.24kg/cm2

Occupied floor pressure 537 psf 25.71 kPa2622 kg/m2

Note: Floor loading information is approximate anddoes not incorporate different option configurations. Itshould be used only with adequate safety factors.

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice or obligation.

SPECIFICATIONS


Part No. 133546 Z-30/20N • Z-30/20N RJ 35

SPECIFICATIONS

Range of Motion

Range of Motion for Rotating Jib

10 ft3 m

5 ft1.5 m

0 ft0 m

0 ft0 m

5 ft1.5 m

10 ft3 m

15 ft4.6 m

20 ft6.1 m

+75°

-67°

25 ft7.6 m

30 ft9.1 m

15 ft4.6 m

20 ft6.1 m

25 ft7.6 m

Operator’s Manual€¦ · Fifth Edition • Third Printing Operator's Manual Part No. 133546...

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